3 TwinCAT e - BECKHOFF New Automation Technologybeckhoff.nl/beckhoff.nl/dutch/e-presentation/cx1000ws/3...TwinCAT process image field bus 1 field bus 2 field bus 3 Mapping 10.02.2009

10.02.2009 Beckhoff TwinCAT 1

Beckhoff TwinCAT The Windows Control and Automation Technology

Beckhoff Industrial PC

Beckhoff Drive Technology

Beckhoff Lightbus

Beckhoff TwinCAT

Beckhoff Bus Terminal

Beckhoff Fieldbus Box

Beckhoff Embedded PC

Beckhoff PC Fieldbus Cards, Switches

Beckhoff EtherCAT


PC control technology – PLC and NC on a PC


Contents

• PC based automation

• TwinCAT

• overview

• I/O

• control (plc)

• motion (nc ptp)

• interpolated motion (nc-i, cnc)


CP

U

NC

E/A

Evolution in control

Hardware �� SoftwareMechanic �� Electronic

Slots/CPUs ��Taskspar. Connect �� FieldbusComm. �� direct Access

IPC

Prog.Tool

HMI

IPC

Komm.

Fieldbuses

Prog.Tool

HMI

Router

PL

C 1

NC

E/A

Mapping

..

RT

-Kern

el

PL

C 2

PC based automation: development


What is TwinCAT ?

TwinCAT is an automation packagecomprising engineering and runtime software for

• sequence control (Software PLC),

• motion (Software Motion Control),

• communication over all components (ADS),

• technological function (controllers,

communication, OS functions, etc...)

and all this in HARD REALTIME on Windows NT/2000/XP

as well as on Windows NT/XP Embedded and CE.NET.


TwinCAT architecture

TwinCAT on a PC platform

TwinCAT� does not modify Windows� needs no special hardware � turns standard Windows to a real-time OS� Floating Point Unit (FPU) fully supported� full access to Windows user interface via OCX, Dll� remote access via TCP/IP

PC platform� standard hardware, best performance� use of PC resources� use of mainstream operating system (Windows)� easy integration into office networks� open field bus communication


Windows NT, 2000, XP

Fieldbus Card Drivers

ADS Router

I/OServer

I/O Mapping

PLCServer

I/O

NCServer

otheri.e. CAM

SysMan

ADS

PLC Control

Diagnosei.e. Scope

UserHMI

UserHMI

OPCOCX/DllTCP/IP

Kern

elm

od

eU

serm

od

e

ADSADS ADS OPC

ADS ADS ADS ADS

I/O I/O

TwinCAT System

Realt

ime

Serv

er

Platform PC


TwinCAT real-time

• developed by Beckhoff

• needs no extra hardware other than PC

• cycle times as low as 50 µs

• preemptive scheduling

• latency time < 15 µs (PIII)

• adjustable real time ratio to Windows

(patented)

• message if latency time is too high


TwinCAT PC system key features

Safe operation � TwinCAT real-time systems survive a BSOD

(blue screen of death)� motherboard diagnosis for fan/temperature

Performance � fast closed loop control, cycle time down to

50 µs

Vertical and horizontal integration � ADS routing (local or via TCP/IP)

Retain data/restart behaviour� UPS support (serial and Beckhoff)

Event tracking


TwinCAT on a CX1000/CX1020/CX9000 platform

TwinCAT

� pure software solution

� uses Windows CE real-time

� cyclic storage of Retain Data

� programming display

CX10xx/CX9000

� embedded HW: 32-bit x86 comp. CPU 266 MHz

� OS: Windows CE or Windows XP embedded (CX10xx)

� no rotating media, fan less

� direct access to terminal I/O

� more than one field bus

� master and/or slave

� resolution from 320 x 240 to 1024 x 768


TwinCAT CE system key features

Safe operation � TwinCAT real-time systems survive a

BSOD (blue screen of death)� Motherboard diagnosis for

fan/temperature

Performance � fast closed loop control, cycle

time down to 50µs

Vertical and horizontal integration � ADS Routing (local or via TCP/IP)

Retain data/restart behaviour� UPS support (serial and Beckhoff)

Event tracking � language independent messages


TwinCAT on a BXxxxx platform

TwinCAT• downloads program• source code up/download • online debugging/online change• remote access via field bus

BXxxxx • embedded hardware• Smart System Bus

(CANopen based) • display • navigation switches• embedded operating system• direct access to terminal I/O


TwinCAT on a BCxxxx platform

TwinCAT• downloads program • online debugging• remote access via field bus

BCxxxx • embedded hardware • embedded operating system• direct access to terminal I/O


Test 1 : Bit / Byte / Int / Dint / Word / DWord Test 2 : Bit / Byte / Int / Dint / Word / DWord / Real / LReal / String

Performance Measurements


TwinCAT I/O System

• open for all major field buses

• PC hardware supported

• easy setup and diagnosis

• mapping from logical tophysical I/O

II OO

InputInput OutputOutput

II OO II OO

TwinCAT process image

field bus 1 field bus 2 field bus 3

Mapping


TwinCAT Control

modular structure

• max. 4 PLCs on a PC

• 1 PLC on CX1000/BX/BC

timing

• max. 4 task in one PLC

easy set up and maintenance

• online program change

• full debugging features:

• breakpoint, monitoring, power flow, scope

choose the favourite programming language

• all IEC61131-3 languages

(IL, ST, FBD, LD, SFC)


TwinCAT Motion

Migration from mechanical to electronic system� mechanical cam �� electronic cam� mechanical gear �� electronic gear� mechanical clutch �� electronic coupling� mechanical cam shaft �� electronic cam shaft� flying saw

Benefit� greater flexibility when changing the finished

product� increase machine output� reduce set up time – no mechanical modification� decrease stock – no different mechanical parts

Summary�� shorten delivery/development time, decrease costs


TwinCAT NC PTP

� up to 255 axes� easy set up and maintenance� open for all axis types� servos� stepper� switching axes� hydraulic axes� interfacing to drives via � digital interfaces:

Lightbus, Sercos, Profibus DP/MC, SSI, pulse train

� analogue: +-10V � additional functionality: camming,

gearing, flying shear, superposition


Hands on


Interpolated movements: TwinCAT NC I

Interpolated movements for 3-

axes plus 5 auxiliary axes

�programming in DIN 66025 Code

�technological features: bottleneck detection


TwinCAT NC I

Linear, circular, helical interpolation in the main planesLook Ahead

Interpolation functions

DIN 66025 extensionHigh-level language extensionsSubroutine techniquesCNC function blocks from the PLC

CNC programming

IEC 61131-3PLC programming

255313 path axes + 5 auxiliary axes

Max. number of controlled axesMax. number of independent channelsMax. number of simultaneously interpolating per channel

TwinCAT NC IProperties


TwinCAT NC I

Coordinate transformationReal-time transformations

Analog/encoder axis interface via appropriate fieldbusDigital axis interface via Lightbus, Sercos, Profibus DP/MC,CANopen, real-time Ethernet

Axis interface

Lightbus fieldbus system, Profibus DP, CANopen, DeviceNet, Interbus, Sercos, real-time Ethernet, PC interfaces

I/O system

Path overrideAxis fault/sag compensationGantry axesTracking axesAuxiliary axesMaster/Slave coupling variable factorAxis exchange via channelsOnline changes of configuration of the axesOnline axis exchange with PTP axes

Axis functions

TwinCAT NC IProperties


TwinCAT CNC

�CNC path control for highest demands

�complete CNC functionality

�32-axis interpolation

�coordinate and kinematiktransformation

�5-axis functionality

�spline interpolation


TwinCAT CNC

Linear, circular, helical interpolation in the main planes/freely definable planesLook AheadSpline interpolationThread functions

Interpolation functions

DIN 66025 extensionHigh-level language extensionsSubroutine techniquesUser macros

CNC programming

IEC 61131-3PLC programming

3212

10

32 path axes/spindles

Max. number of controlled axes/spindlesMax. number of controlled spindlesMax. number of independent channelsMax. number of simultaneously interpolating per channel

TwinCAT CNCProperties


TwinCAT CNC

Coordinate and kinematic transformation5-axis functionality

Real-time transformations

Analog/encoder axis interface via LightbusDigital/encoder axis interface via Lightbus,Sercos, Profibus, DP/MC

Axis interface

Lightbus fieldbus system, Profibus DP, CANopen, DeviceNet, Interbus, Sercos, real-time Ethernet, PC interfaces

I/O system

Path overrideAxis fault compensationGantry axesTracking axesAuxiliary axesMaster/Slave couplingAxis/spindle exchange via channelsSpindle synchronisation

Axis functions

TwinCAT CNCProperties


Performance

BCxxxxBXxxxx

CX1010

PC

Costs

for all Platforms

TwinCAT: One Tool

TwinCAT: PLC

TwinCAT PLC

CX9xxx

CX1020/30


Performance

BCxxxxBXxxxx

CX1010

PC

Costs

for all Platforms

TwinCAT: One Tool

TwinCAT: NC PTP

TwinCAT NC PTP

CX9xxx

CX1020/30


Performance

BCxxxxBXxxxx

CX1010

PC

Costs

for all Platforms

TwinCAT: One Tool

TwinCAT: NC I

TwinCAT NC I

CX9xxx

CX1020/30


Performance

BCxxxxBXxxxx

CX1010

PC

Costs

for all Platforms

TwinCAT: One Tool

TwinCAT: CNC

TwinCAT CNC

CX9xxx

CX1020/30


Centraal vs Decentrale Motion Control

Centraal

+ Alle data (instellingen, status) op één locatie

+ Meerdere assen zijn eenvoudig te coördineren

+ Applicaties zijn eenvoudiger te multipliceren

+ Backups zijn eenvoudig te maken

+ Minder spareparts

- Er is een krachtige CPU nodig

Decentraal

- Alle data (instellingen, status) verspreid over de diverse controllers

- Meerdere assen zijn moeilijk te coördineren

- Applicaties zijn lastig te multipliceren

- Backups zijn lastig te maken

- Meer spareparts

+ Er is niet zo’n krachtigeCPU nodig


Voordelen Motion Control met TwinCAT

• Geen dure hardware motion controller nodig

• Alle informatie op één plek

• Krachtige Scoop functie

• Nagenoeg veldbus onafhankelijk

• Geïntegreerde PLC (zelfs 4 PLC’s op één PC)

• Motion Control Library volgens PLCopen

• Software kan al met standaard PC ontwikkeld en getest worden

• Extreem flexibel

• Van NC PTP via NCI naar CNC

Documents

3 TwinCAT e - BECKHOFF New Automation Technologybeckhoff.nl/beckhoff.nl/dutch/e-presentation/cx1000ws/3...TwinCAT process image field bus 1 field bus 2 field bus 3 Mapping 10.02.2009